Joining structure of packaging container

ABSTRACT

A joining structure of a packaging container is divided into at least two packaging members, and the joining structure includes: first slits formed in a dividing direction and located on both side of at least one corner of a joining-side end of a first packaging member, the first packaging member and a second packaging member being joined to each other; an engaging corner formed at a joining-side end of the second packaging member, the engaging corner being engaged with each of the first slits and being located on an inner side of a corner of the first packaging member, the engaging corner being formed at a corner corresponding to the corner of the first packaging member; and a cover that continues to the engaging corner and is located to cover an outer side of a joining end of the first packaging member on an outer side of the first slits.

The entire disclosure of Japanese patent Application No. 2018-175122, filed on Sep. 19, 2018, is incorporated herein by reference in its entirety.

BACKGROUND Technological Field

The present invention relates to a joining structure of a packaging container that accommodates a device and the like therein.

Description of the Related Art

In a case where a packaging container that accommodates an information device such as a copying machine has a great height or the like, a space for removing the outer packaging material cannot be maintained above the packaging container, and the packaging container collides with the ceiling. For example, in a case where the packaging container has an outer packaging material with a greater height than 140 cm when the information device has a height of 143 cm or greater, the installation ceiling height is 3 m, and the packaging pallet height is 15 cm, the packaging container hit the ceiling, and therefore, it is difficult to remove the packaging container.

If it is possible to tilt a packaging container in a packaged state like a packaging container containing a refrigerator or the like, the packaging box can be pulled off in the height direction. However, in a case where an information device or the like is accommodated, a pallet is also packaged according to the specifications in some cases. In such a case, it is difficult to tilt the packaging container, and as a result, unpackaging is restricted.

In a conventional packaging container according to JP 9-286430 A, for example, an upper plate 1 and a lower plate 4 have guidelines 3 and 6 for forming handle holes 2 and 5 and side plates 7 and 8, respectively. When the upper plate 1 and the lower plate 4 are made to face each other to form a U-shape and are put on each other, the handle holes overlap to form through holes 12. The through holes 12 are filled with a stopper (including tape, wire, and adhesive) 13, so that the side plates 7 and 8 are joined to each other, to form a box-like structure with the upper plate 1 and the lower plate 4.

JP 2005-67657 A provides a technique for minimizing the amount of foam plastic or the like in a case where a heavy-weight machine such as a printer is packaged, and facilitating collection and disposal of the packaging material and lowering the costs for packaging. Cushioning of the side surfaces of the product is achieved with a body frame and a band that wrap the product, so that the cushioning material for the side surfaces is omitted to lower the costs. Specifically, two rows of slits of a constant length perpendicular to the vertical lines are formed in the middle of the vertical lines at the four corners of the packaging box body. The portions between the slits in the two rows are bent inward in a W-shaped step-like form in a plan view in the packaging box body. As a result, W-shaped recesses are formed at the four corners of the packaging box body. Banding is then performed through the W-shaped recesses, to tighten the four corners of the product from the outside the product accommodated in the box, and integrate the product and the packaging box body.

The structure according to JP 2014-201340 A is a structure that includes first and second cylindrical members having the same shape in a direction orthogonal to the axis line, and has the first and second cylindrical members joined with joining end portions. Each of the joining end portions has first and second slits extending from the edge toward the axis line, an outer overlapping portion positioned on one side between the first and second slits, and an inner overlapping portion located on the other side between the first and second slits. The first slits of the first cylindrical member are engaged with the first slits of the second cylindrical member, and the second slits of the first cylindrical member are engaged with the second slits of the second cylindrical member. Alternatively, the second slits of one of the first and second cylindrical members are engaged with the wall surfaces of the joining end portions of the other one of the first and second cylindrical members, and the outer overlapping portion of one of the first and second cylindrical members is made to overlap with and is joined to the outer side of the inner overlapping portion of the other one of the first and second cylindrical members.

JP 2013-233950 A discloses a two-piece packaging box that includes an exterior case (1) having an open bottom and a tray (2) covered with the exterior case (1) from above. An engaging piece (10) is formed at the rim of a sidewall (3) of the exterior case (1), and the portion between cutting lines (12) extending from both ends of the base of the engaging piece (10) serves as a releasing piece (13). A sidewall (22) of the tray (2) has a multilayer structure, and a recess (28) is formed in an outer surface of the multilayer structure. The engaging piece (10) is bent inward, and the rim of the sidewall (3) of the exterior case (1) is put on the outer side of the sidewall (22) of the tray (2), so that the engaging piece (10) is engaged with the recess (28), and the exterior case (1) and the tray (2) are secured to each other. When the releasing piece (13) is roiled up to cut along the cutting lines (12), the exterior case (1) and the tray (2) are detached from each other.

In JP 9-286430 A, however, the two plates of the upper and lower plates require the stopper at the time of packaging, and therefore, a component other than the box material (such as cardboard) is necessary.

JP 2005-67657 A discloses a structure in which a packaging material is put on the bent portions at the four corners. However, the packaging material is not supported in a lateral direction, and is allowed to move.

In JP 2014-201340 A, two members having slits of the same shape are joined, which restricts shape. Further, the outer overlapping portion of one of the first and second cylindrical members is made to overlap with the outer side of the inner overlapping portion of the other one of the first and second cylindrical members, and therefore, a sufficiently high rigidity cannot be obtained. Furthermore, where slits are formed in the outer shape, the length of the outer periphery increases. As a result, the rigidity becomes lower particularly around the slits

In JP 2013-233950 A, removal of a packaging container is not improved.

SUMMARY

The present invention has been made in view of the above circumstances, and an object thereof is to provide a joining structure of a packaging container that enables easy unpackaging even when there is only a small space around.

To achieve the abovementioned object, according to an aspect of the present invention, there is provided a joining structure of a packaging container that is divided into at least two packaging members, the packaging members being joined to each other to form the packaging container, and the joining structure reflecting one aspect of the present invention comprises: first slits that are formed in a dividing direction and are located on both side of at least one corner of a joining-side end of a first packaging member, the first packaging member and a second packaging member of the at least two packaging members being joined to each other, an engaging corner formed at a joining-side end of the second packaging member, the engaging corner being engaged with each of the first slits and being located on an inner side of a corner of the first packaging member, the engaging corner being formed at a corner corresponding to the corner of the first packaging member, and a cover that continues to the engaging corner and is located to cover an outer side of a joining end of the first packaging member on an outer side of the first slits, wherein the engaging corner has a shape to be located to face an inner surface of the corner of the first packaging member via a space.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and features provided by one or more embodiments of the invention will become more fully understood from the detailed description given hereinbelow and the appended drawings which are given by way of illustration only, and thus are not intended as a definition of the limits of the present invention:

FIG. 1 shows perspective views for explaining separating and joining of packaging members in a packaging container in one embodiment of the present invention;

FIG. 2 shows enlarged views of a joined portion in the packaging container shown in FIG. 1;

FIG. 3 is a diagram for explaining an example of packaging;

FIG. 4 shows enlarged views of a joined portion in the packaging container shown in FIG. 3;

FIG. 5 is a diagram showing another joining structure in a packaging container;

FIG. 6 is a diagram for explaining behaviors against a load in an embodiment of the present invention and a conventional example;

FIG. 7 is a diagram for explaining commonalization in a conventional example and an embodiment;

FIG. 8 is a diagram for explaining an example of commonalization using a size standard;

FIG. 9 is a diagram for explaining an example of a conventional structure;

FIG. 10 is a diagram for explaining another example of a conventional structure; and

FIG. 11 is a diagram for explaining an example structure of a conventional packaging container.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, a joining structure of a packaging container according to one or more embodiments of the present invention will be described with reference to the drawings. However, the scope of the invention is not limited to the disclosed embodiments.

A packaging container 1 includes packaging members 2 and 3 obtained by separating a packaging member into upper and lower portions. The left half of FIG. 1 shows the packaging members 2 and 3 in a separated state. The right half of FIG. 1 shows the packaging members 2 and 3 in a joined state.

In this embodiment, the packaging container 1 is divided into two packaging members in the height direction, but the dividing direction is not limited to any particular direction in the present invention. For example, the packaging container 1 may be divided in a horizontal direction or an oblique direction, or may be divided in a plurality of directions.

In the packaging members 2 and 3, slits 21 are formed vertically, or in the dividing direction, at the upper ends on both sides of each of the four corners 20 of the packaging member 2. Slits 31 are formed horizontally, or in a direction orthogonal to the dividing direction, at the lower ends of the four corners 30 of the packaging member 3, and the lower sides of the slits 31 are bent inward, to form internal angles. The bent portions are equivalent to engaging corners 32 of an embodiment of the present invention. The corners 20 and 30 are angled portions.

Accordingly, in this embodiment, the packaging member 2 is equivalent to a first packaging member of an embodiment of the present invention, the slits 21 of the packaging member 2 are equivalent to first slits of an embodiment of the present invention, the packaging member 3 is equivalent to a second packaging member of an embodiment of the present invention, and the slits 31 of the packaging member 3 are equivalent to second slits of an embodiment of the present invention.

FIG. 2 shows the above configuration in detail. In the packaging member 3, at the positions corresponding to the slits 21 at the corners 20 of the packaging member 2, the lower ends are bent inward to form the engaging corners 32 each having an internal angle of approximately 90 degrees, and both ends of each of the engaging corners 32 are engaged with the slits 21 and are joined thereto.

The length of the slits 21 is greater than the longitudinal length of the engaging corners 32 under the slits 31.

Above the engaging corners 32, the lower end surfaces of the packaging member 3 overlap with the outer sides of the upper ends of the corners 20 of the packaging member 2. Further, on both sides of each of the engaging corners 32, lower portions of the packaging member 3 join thereto, and the lower portions serve as covers 33 overlapping with the outer sides of the upper ends of the packaging member 2. In this embodiment, the covers 33 overlap with the upper end portions of the packaging member 2, but there may be a space in between. By adjusting the length of the slits 21, it is possible to adjust the overlap of the engaging corners 32 and the covers 33 with respect to the packaging member 2.

In this embodiment, the engaging corners are bent inward, so that the length of the outer periphery of the packaging member does not become greater, and rigidity can be maintained.

Although the slits 21 are located on both sides of the corners the positions thereof are not limited to any particular positions. If the slits are located far away from the corners, the rigidity will become lower. For this reason, the position of each slit is preferably ¼ or less of the size of the packaging member, for example. The specific length is preferably 20 to 30 cm at a position within 50 cm from the center of the corresponding corner, though the specific length depends on the size of the packaging member.

Conventional packaging containers having problems are now described.

FIG. 9 illustrates a case where an image forming apparatus is packaged as a heavy-weight information device in a packaging container. This packaging container includes a packaging box in the form of a sleeve (a copper box) as its main component, and also includes a bottom cover and a top cover. The packaging box has a shape without top and bottom flaps.

For example, if the pallet height is 150 mm, and the product height is 190 cm in a space with a ceiling height of 3 m, a box with a height exceeding 140 cm has a problem that the box will collide with the ceiling at the time of unpackaging.

There are other known packaging containers that are manufactured with joints.

As shown in FIG. 10, a packaging container is delivered in a panel-like form, is wound around a product, and is joined with joints (made of resin). For example, one or two pieces of cardboard, and four to eight joints are used. In packaging, the joints are inserted into holes, and are locked. In unpackaging, the joints are unlocked and removed, and the cardboard is opened.

In this configuration, joining can be performed after the packaging container is wound around a product. Accordingly, a space in the height direction is not necessary, and joints can be repeatedly attached and detached. Thus, it is possible to cope with a situation where the contents need to be corrected.

However, in a case where the joints are expensive, and only one piece of cardboard is used, the cardboard will take up a lot of space at the time of delivery. In a case where two pieces of cardboard are used, two people might be required for delivery.

Other than the above, there are other known packaging containers that are manufactured by stitching.

In this method, a packaging container is delivered in a panel-like form, is wound around a product, and is joined by stitching. This packaging container can be formed with one piece of cardboard.

In packaging, cardboard joints are stitched together, and are then covered with a sleeve from above. In unpackaging, the portions near the joined portions are cut, so that the cardboard is opened.

The manufacturing of this packaging container advantageously requires low costs.

However, the manufacturing of this packaging container has the following drawbacks.

A space in the height direction is necessary to form the shape of the sleeve in advance.

In a case where one piece of cardboard is used, the cardboard will take up space at the time of delivery.

In a case where any of the above two types of packaging containers is covered with a sleeve, an overlapping portion is formed as shown in the left half of FIG. 11, so that a packaging container of such a size as not to collide with the ceiling can be prepared. On the other hand, in a case where a packaging container is not covered with a sleeve, the packaging container is prepared with joints. With the above manufacturing method, the packaging container shown in FIG. 10 is more expensive, and therefore, the stitched packaging container is preferentially used.

As described above, in the above two types of packaging containers, fasteners or the like need to be included among the components. Therefore, components other than the box material (such as cardboard) become necessary. Some fasteners can be diverted while other fasteners cannot, which results in lack of versatility.

In this embodiment, on the other hand, it is possible to form a packaging container with a single member (material) as will be described later, and accordingly, can be more easily separated and be produced at lower costs than a structure using joining members that can be easily separated.

Next, an example of packaging of this embodiment is described, with reference to FIGS. 3 and 4.

A bottom view (the upper side) and a side view (the lower side) of the packaging member 2 (shown as A for convenience in the drawing) are shown at the left side in FIG. 3. To the right, a bottom view (the upper side) and a side view (the lower side) of the packaging member 3 (shown as B for convenience in the drawing) are shown. Further to the right, a bottom view (the upper side) and a side view (the lower side) of the joined packaging container in a cross-section taken along the joining line are shown.

An information device having a weight in the range of several tens of kilograms to several hundreds of kilograms is shown as an example product. However, the contents are not limited to any specific product in this embodiment.

In this embodiment, of the four corners of the packaging member 3, three corners 30 have the above described engaging corners 32, and the remaining one corner does not have any second slit and any engaging corner bent inward, but has a corner 30A that is made oblique between the positions corresponding to the slits of the packaging member 2. This corner is referred to as the engaging corner 32A.

In this embodiment, being a stitch portion, the one corner is made oblique to avoid having slits formed therein. It is of course possible to form an engaging corner 32 like the other corners, instead of the stitch portion. Alternatively, it is also possible to make all the four corners oblique in the packaging member 3. In this case, the packaging member 3 has an octagonal cross-section.

As shown at the right side in FIG. 3, the packaging members 2 and 3 have a handle or the like for unpackaging, and are joined to each other.

As a two-tiered structure is formed with upper and lower members, the space required in the height direction is reduced by half when a sleeve is put on the product, and thus, packaging and unpackaging can be performed by one person.

The positions of the packaging members 2 and 3 in the vertical direction are not particularly limited, and the packaging member 3 may be placed on the lower side while the packaging member 2 is placed on the upper side. Furthermore, the number of separate packaging members may be three or larger.

FIG. 4 is a diagram for explaining the packaged state shown in FIG. 3.

This diagram specifically shows the joined state in which a corner of the packaging member 3 is not an angled portion but an oblique surface. In this packaging member 3, the engaging corners 32 are formed at three corners 30, and the engaging corner 32A having an oblique surface is formed at the corner 30A. The respective engaging corners 32 and 32A are engaged with the slits 21 of the packaging member 2, and the packaging member 2 and the packaging member 3 are then joined to each other.

FIG. 5 is a diagram for explaining a modification. This modification has corners 30 at the four corners thereof, slits 31 are formed in the respective corners 30, and lower portions of the corners 30 are bent inward, to form engaging corners 32, as in the embodiment described above.

In this modification, slits 34 in the dividing direction or the height direction are further formed at the respective engaging positions of the engaging corners 32 with respect to the slits 21. The slits 34 correspond to third slits of an embodiment of the present invention.

The slits 34 have a length that is smaller than the height of the engaging corners 32. The engaging corners 32 and the covers 33 are connected by the sides on the slits 34. The slits 34 are smaller in length than the slits 21, and the length can be used to adjust the ratio of the length of the engaging corners to the length of the slits 21.

Next, a packaging container formed with a joining structure of a packaging container of an embodiment of the present invention, and the rigidity of a convention packaging container are described, with reference to FIG. 6.

The diagrams in the upper portion of FIG. 6 show a packaging container of a conventional example. If a load is applied to a packaged product from a side, the packaging material might be crushed at a side length L and collide with the product, as shown in the second drawing from the right, which shows an A-A cross-section.

In the embodiment of the present invention, on the other hand, there is a distance to the product even if the packaging material is crushed due to a load applied from a side. Further, as a side length L2 is shorter than the conventional side length L1 (L1>L2), the deflection is smaller.

Deformation of the packaging material due to a load is restricted by the slit and engaging portions of the four corners, so that an effect to reduce deformation of the entire packaging material can be expected.

In this embodiment, the total number of packaging members 2 and packaging members 3 is an odd number, and the number of the packaging members 3 is larger than the number of the packaging members 2.

Further, the outer size of the packaging member 2 in the horizontal direction, that is, the outer size in a direction orthogonal to the dividing direction, can be made smaller than the outer size of the packaging members 3 in the horizontal direction.

In an embodiment of the present invention, the joining structure can be further simplified, and the same package can be used for different products.

The diagrams in the upper portion of FIG. 7 illustrate example cases with conventional packaging containers.

In a case where there is the packaging container shown in the upper left diagram, if the device becomes higher or a space for accessories is required, it is necessary to prepare a different packaging container as shown in the upper middle diagram or in the upper right diagram.

In the embodiment of the present invention, on the other hand, part of the package may be made common in packaging products that differ in having accessories or the like, as shown in the lower portion of FIG. 7. In this example, a packaging member A may be made common, and packaging members B, C, . . . may be added as appropriate, to form a packaging container. As the number of non-common packaging members becomes smaller, it becomes easier to create packaging containers, and lower production costs.

Likewise, in a case where part of printing is changed, it becomes easier to make the change with small packaging members.

That is, even if the height of the contents changes, another packaging member having a different height is prepared while the common packaging member is still used. These packaging members are then joined, so that a packaging container can be obtained.

Although a case with different heights has been described, there are cases where widths are different while heights are the same. In such a case, it is necessary to prepare packaging members, depending on changes in size.

For example, as shown in FIG. 8, in a case where packaging boxes for Model 1 and a minor change in Model 1 need to be prepared, a standard size is set for common packages as shown in the lowermost diagram in FIG. 8, and the packages are produced in the same manner (such as printing and preprocessing for forming slits and engaging portions). The common packages are then cut in accordance with the usage size, and thus, packaging members can be produced.

In this embodiment, the cardboard of a packaging box to be used for an information device is thicker and stronger than general-purpose cardboard. Therefore, even if slits are formed at the angled portions or in the vicinities of the angled portions, it is possible to maintain strength (not in the vertical direction though) by combining the cardboard with the cardboard of another packaging box.

As for a package to be divided, it is necessary to reduce the tolerance between the two sizes or allow rattling between the two components. Even in a large-size package for which dimensional control is difficult, it is possible to increase the tolerable size difference and reduce rattling, by combining two members with slits.

In this embodiment, the allowable range for dimensional tolerance between two components is wide. (In the case of connection with a level difference between the upper and lower components, the demand for dimensional control is strong).

It is possible to secure a power supply only by unpackaging the upper exterior package, it is possible to recover the ROM and the like, and it is easy to return an unpackaged product to the packaged state (in a situation where unpackaging and setup is to be performed, there is no possibility of receiving impact from a side or the like, and a sufficient strength is maintained in the structure).

If the amount of packaging varies with different specifications, the same packaging boxes can be used or applied (FIG. 6).

In the upward and downward directions, a high strength is not always maintained, because the areas of the upper and lower joined portions are small. However, a high strength is maintained for a load applied from a side. The five freedom degrees excluding the dividing direction of packaging members can be controlled.

According to an embodiment of the present invention, the following effects can be achieved.

-   -   In a small space, such as a place with a low ceiling,         unpackaging can be easily performed, despite the small space.     -   Unlike an outer package of a horizontally-opening packaging box         formed by one-side stitching or the like using existing joining         members, an embodiment of the present invention does not require         any high-cost joining members (except for cardboard), and         accordingly, inexpensive packaging and segregation at the time         of disposal can be easily performed.     -   It is possible to open a packaging box in an upward direction or         the like, without tilting the product. Thus, a person can easily         conduct the unpackaging.

Preferred embodiments are as follows.

-   -   Packaging members are joined to each other with slits formed on         one side of a packaging member, and thus, it is possible to         manufacture a packaging box having a high strength against a         load applied from a side. In a case where a packaging material         is wound around a product with joining members or the like, the         end portions might move at the time of unpackaging, and there is         a possibility that the packaging box will collide with the         product, surroundings, or people.     -   Information devices require packaging boxes of slightly         different sizes due to various specifications and minor changes.         However, with a divided packaging structure, the necessary base         material can be made smaller and simplified, and the slit         structure can be easily developed into different sizes.     -   It is possible to make part of a packaging box common, by         printing print information necessary for a packaging box on the         packaging members separately from each other. For example, a         company name or the like may be printed on a first packaging         member that can be used in common, and machine information or         the like may be printed on a second packaging member.

Although embodiments of the present invention have been described and illustrated in detail, the disclosed embodiments are made for purposes of illustration and example only and not limitation, and appropriate modifications may be made to them without departing from the scope of the present invention. The scope of the present invention should be interpreted by terms of the appended claims. 

What is claimed is:
 1. A joining structure of a packaging container that is divided into at least two packaging members, the packaging members being joined to each other to form the packaging container, the joining structure comprising: first slits that are formed in a dividing direction and are located on both side of at least one corner of a joining-side end of a first packaging member, the first packaging member and a second packaging member of the at least two packaging members being joined to each other, an engaging corner formed at a joining-side end of the second packaging member, the engaging corner being engaged with each of the first slits and being located on an inner side of a corner of the first packaging member, the engaging corner being formed at a corner corresponding to the corner of the first packaging mender; and a cover that continues to the engaging corner and is located to cover an outer side of a joining end of the first packaging member on an outer side of the first slits, wherein the engaging corner has a shape to be located to face an inner surface of the corner of the first packaging member via a space.
 2. The joining structure of the packaging container according to claim 1, wherein the second packaging member has second slits in a direction orthogonal to the dividing direction, the second slits being located at a corner of a joining-side end, and the corner located on a tip side of the second slits is bent inward, to form the engaging corner.
 3. The joining structure of the packaging container according to claim 2, wherein a length of the first slits of the first packaging member is greater than a length from a position of the second slits of the second packaging member to the joining-side end.
 4. The joining structure of the packaging container according to claim 2, wherein the engaging corner of the second packaging member has third slits formed in the dividing direction, the third slits being inserted into the first slits.
 5. The joining structure of the packaging container according to claim 4, wherein a length of the third slits is smaller than a length of the first slit.
 6. The joining structure of the packaging container according to claim 1, wherein the engaging corner is former with a sloping surface that is the cover bending inward at both side of the corner of the second packaging member.
 7. The joining structure of the packaging container according to claim 1, wherein at least one of the corners of the first packaging member and the second packaging member has an angled portion.
 8. The joining structure of the packaging container according to claim 1, wherein, when the number of packaging members to be joined is an odd number not smaller than three, the number of the second packaging members is larger than the number of the first packaging members.
 9. The joining structure of packaging containers according to claim 1, wherein at least one of the dividing directions is a height direction.
 10. The joining structure of the packaging container according to claim 1, wherein an outer size of the second packaging member is larger than an outer size of the first packaging member, each outer size being in a direction orthogonal to the dividing direction.
 11. The joining structure of a packaging container according to claim 1, wherein slits corresponding to sizes of packaging boxes are formed in the same packaging member, to allow the packaging member to be used for packages of different sizes. 